CN110936174B - Design method of compressor blade digital full-automatic production line - Google Patents
Design method of compressor blade digital full-automatic production line Download PDFInfo
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- CN110936174B CN110936174B CN201911180288.4A CN201911180288A CN110936174B CN 110936174 B CN110936174 B CN 110936174B CN 201911180288 A CN201911180288 A CN 201911180288A CN 110936174 B CN110936174 B CN 110936174B
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Abstract
The invention provides a design method of a compressor blade digital full-automatic production line, which comprises the steps of firstly determining that a milling and turning combined machining process is mainly used as a main technological process of a blade, and selecting corresponding equipment according to the technological process; determining storage and logistics conveying equipment required by an automatic replacement scheme of the process; determining the production beat according to the requirement of the product capacity; planning and arranging the production line body; production line production debugging test; comprehensively evaluating the capacity of the production line; optimizing a production line; and putting the production line into production and formally executing batch production tasks. The method can be used for designing a compressor blade digital production line, realizing automatic loading and unloading, automatic processing, detection and grinding and polishing of the compressor blade in the whole process, and achieving the purpose of no human intervention in the line; the problem of production plan mixed line control is solved, and various different blades can be simultaneously machined according to production tasks and orders.
Description
Technical Field
The invention belongs to the technical field of digital manufacturing, and particularly relates to a mixed line production line design and application of various and small-batch aero-engine compressor blade parts.
Background
The blade part is the core part of an aeroengine, the compressor blade is the main part for compressing air in the engine, and the manufacturing quality of the compressor blade directly influences the service performance and the service life of the engine. The gas compressor blade part has the problems of low repeated positioning precision, personal error, difficulty in controlling production rhythm and the like in the processing process due to poor blank consistency, complex process arrangement and discrete working procedures, so that the blade part is poor in processing precision, low in efficiency and high in rejection rate and is always the bottleneck problem in the aviation manufacturing industry.
An automatic production line refers to an organization form for realizing a product process by an automatic machine system. The automatic production line has the main advantages that the automatic production line is adopted in mass production, the labor production efficiency can be improved, the product quality is stabilized and improved, the labor condition is improved, the production floor area is reduced, the production cost is reduced, the production period is shortened, the production balance is ensured, and the obvious economic benefit is achieved. Automatic production lines automatically operate or control processes according to prescribed programs or instructions without human intervention, with the goal of "stable, accurate, fast". The application in the fields of food and beverage manufacturing, plastic products, chip manufacturing, electronic circuit boards, automobile manufacturing, electric appliance manufacturing and the like has achieved remarkable effects. However, the aero-engine product has complex process, high precision requirement, large processing difficulty, relatively discrete working procedures, high design difficulty of an automatic production line scheme and long debugging period, only an automatic processing unit facing a single working procedure is realized at present, and an automatic production line is not formed yet.
Disclosure of Invention
The invention provides a design method of a digital full-automatic production line of compressor blades, which aims to solve the problem of logistics control after blades enter the production line from a blank state and realize material transfer, loading, unloading, assembly, positioning, alignment, processing, cleaning, inspection and detection without manual intervention. The method solves the problem of mixed line control of the production plan, and can realize simultaneous processing of various blades according to production tasks and orders. Meanwhile, the problem of shutdown of the production line during production emergencies is solved, the shutdown of any single equipment is realized except for normal maintenance shutdown of the production line, the production line does not stop production, and an automatic solution is provided for small-batch discrete manufacturing.
The technical scheme of the invention is as follows:
a design method for a digital full-automatic production line of a compressor blade comprises the following steps:
firstly, according to the structural requirements of the design structure of the blade, the structural characteristics of double shaft necks, citron plates, blade bodies and micro-radius blade shoulder arcs are used for determining that the blade mainly uses a milling and turning composite turning process as a main process, a high-precision numerical control machining center with a five-axis milling and turning composite turning function is selected as main mechanical machining equipment according to the process, and other auxiliary equipment comprises a cleaning machine, a three-coordinate measuring machine, a polishing machine, a laser marking machine, a thermal expansion instrument, a tool setting instrument, a code reader and a balancing machine;
eliminating human factor influence factors, and determining storage and logistics conveying equipment required by an automatic replacement scheme of the process, wherein the storage and logistics conveying equipment comprises a tower type storage bin, a robot arm, a truss guide rail, an automatic loading and unloading station, a tray warehouse, a robot arm clamping jaw warehouse, a guardrail and a system control software machine;
thirdly, determining the production beat according to the requirement of the product capacity, and using TproduceRepresenting the actual production time per year, N representing the part demand quantity per year, omega representing the part production qualification rate, and the production taktperThe calculation formula of (c) can be expressed as:
with DserviceIndicating the number of days per year that the line needs maintenance, TserviceRepresenting the number of annual services, tupRepresenting the time of starting and closing before and after the production line service, the actual production time calculation formula of the production line per year can be expressed as:
Tproduce＝(365-Dservice)×24h-Tservice×tup
the production line maintenance comprises 1 debugging time per week and 1 day maintenance; debugging for 1 time additionally every month, and maintaining for 2 days; the single debugging is carried out for 1 time every year, and the period is 1 day; the maintenance days per year and the service times per year are respectively as follows:
before and after each service, the system is powered on and powered off for tupAnd 24h, the annual running total time of the production line is as follows:
Tproduce＝(365-77)×24h-65×24h＝5352h
assuming that the annual leaf production demand is 100000 pieces, the annual actual production time T is 98.5% according to the qualification rate omegaproduceFor 5352h calculation, the production beat of the production line provided by the invention is as follows:
fourthly, planning and arranging production line bodies, namely arranging all equipment required by the technological process, balancing the output of the production line according to the principle of minimum equipment, shortest logistics transfer distance, lowest inventory and least production arrangement, and designing the line body arrangement;
whether the production line layout is reasonable or not is mainly measured according to the maximum time loss value of production unbalance, and whether the process is a bottleneck link or not is judged by comparing the production tempo with the production time of a single process;
assuming that a production line has m processes, the standard time consumed by the nth process is tn(n ═ 1,2,3, Λ, m) and the line tact is tperAnd then:
when t isn＞tperIn the process, the time required for finishing the work of the nth process is longer than the production line beat, and the process is a production bottleneck link;
when t isn＝tperThe time required by the processing of the procedure is just equal to the beat of the production line, and the condition is the most ideal state;
when t isn＜tperIn the process, after the nth process finishes working in a production beat, certain residual time is available, which indicates that resources are not fully utilized;
the production line production debugging test is carried out, when all the single equipment meet the requirements of technical conditions, the combined line joint debugging test work is carried out, the correctness of all the programs of the production line is verified, the coordination and unification of all the instructions and corresponding actions are ensured, and the real-time recording and the tracing of production data are realized;
comprehensively evaluating the production line capacity, mainly considering efficiency, cost response degree and product technical specification response degree; evaluating specific indexes of productivity index, machining efficiency matching index, economic index, cost index, delivery cycle, equipment, software, technical scheme and service guarantee; if the production planning requirement is met, jumping to the step (c), and if the production planning requirement is not met, jumping to the step (c);
optimizing the production line, performing simulation verification on the design plan of the production line, analyzing a simulation result, adjusting and optimizing corresponding capacity indexes, production equipment parameters, process methods and logistics transfer processes, and jumping to the fifth step after optimization;
and (8) putting the production line into production and formally executing the batch production tasks.
The compressor blade digital full-automatic production line designed by the method is provided with in-line equipment and out-line equipment, wherein the in-line equipment is mainly used for automatic production, and the out-line equipment is mainly used for tool preparation;
the inline device includes: the device comprises a blade machining center, a tower type storage bin, a cleaning machine, a robot arm, a guide rail, an automatic loading and unloading station, a tray library, a robot arm clamping jaw library, a guardrail, a production system industrial personal computer, a three-coordinate measuring machine, a polishing machine and a laser marking machine;
the off-line device includes: thermal expansion instrument, tool setting instrument and balancing machine.
(1) Blade machining center
A vertical five-axis blade machining center is provided with a main shaft at 30,000rpm, a double-drive shaft at 4,000rpm, a turning function, an automatic workpiece exchange station and a tray pre-selection station. The high-precision measuring head, the cutter identification chip, the main shaft monitoring function, the high-pressure internal cooling function and the cooling liquid constant temperature function are arranged. All the characteristics of the blade, including round handle, screw thread, profile, air inlet and outlet edges, blade root, blade crown and switching are processed and finished on the blade processing center.
(2) Tower type stock bin
The method is mainly used for managing the rough materials, finished products and waste products of the blades. Different blade trays are arranged in the storage bin so as to store blades of different models. The blank and the finished product are vertically placed on each layer. Once all the procedures of the blade are finished (milling, turning, polishing, cleaning, detecting and marking), the finished blade is put back to the designated position of the stock bin by a robot arm, and the collision damage is not allowed.
(3) Cleaning machine
The method mainly finishes the cleaning of the blade before processing and measuring, and ensures the cleanness of the blade before measurement and warehousing. The workpiece is moved in and out of the cleaning machine by a robot. The cleaning liquid is recycled after purification.
(4) Robot hand and guide rail
The blade tray is mainly responsible for conveying the blades, the clamps and the blade tray. A 6-axis robot is mounted on the top rail and is movable along the entire unit. The top rail is placed in the middle, and the robot can operate all equipment, a storage bin and a loading and unloading station. The robot arm can be provided with different clamping jaws and can grab trays, blanks, pre-processing or product blades.
(5) Automatic loading and unloading station
The clamp is used for automatically clamping and loosening the clamp. The robot arm can place the clamp and the blade in a loading and unloading area of the automatic loading and unloading station; the loading and unloading mechanism controls torque and speed through a digital motor, and the blades and the clamp are installed and unloaded.
(6) Tray warehouse
Used for storing trays used for all machine tools, cleaning machines, three-coordinate measuring machines and polishing machines.
(7) Robot gripper library
For storing different jaws of a robot, such as a gripping pallet jaw, a gripping blank jaw and a gripping finished blade jaw.
(8) Guard bar
The intelligent emergency stop system is mainly used for being isolated from the outside, and has the functions of safety emergency stop, authority management, alarm prompt and the like. And the safety of related operators is protected.
(9) Industrial control computer of production system
The production cycle scheduling of the ascending control order, the storage and consumption of various parts and tools, the collection of equipment operation data and the storage of the equipment operation data are carried out to carry out statistics and analysis on product quality data; and descending control equipment to operate and various trigger instructions, generating a brand new motion control instruction by the industrial control machine of the production system according to the actual order requirement, sending the brand new motion control instruction to each piece of equipment in the production line, and automatically operating the equipment according to a program after receiving the instruction.
The method mainly comprises the steps of up-down control, production cycle scheduling of an upper control order, storage and consumption of various parts and tools, and statistics and analysis of product quality data by collecting and storing equipment operation data. And descending control equipment to operate and various trigger instructions, generating a brand new motion control instruction by the industrial control machine of the production system according to the actual order requirement, sending the brand new motion control instruction to each piece of equipment in the production line, and automatically operating the equipment according to a program after receiving the instruction.
(10) Three-coordinate measuring machine
The three-coordinate measuring machine is suitable for workshop environment, and an optical measuring head and a tray are integrated on the three-coordinate measuring machine. During measurement, the three-coordinate measuring machine can simultaneously measure the ambient temperature and the workpiece temperature. Two kinds of special software are used to evaluate the blade, mainly to complete the measurement of the size and shape of the blade shape, air inlet and outlet sides, citron plate and other parts. The measuring machine comprises an optical scanning head, and the blade characteristics can be measured by adopting an optical measuring mode and automatically generate a measuring report.
(11) Polishing machine
Mainly finishes the polishing of the leaf shape, the air inlet and outlet edges, the citron plate and other parts of the leaf blade, and the surface roughness Ra is 0.4 after the polishing. The polishing machine comprises a robot hand, different grinding tools can be used, and unattended processing can be performed.
(12) Laser marking machine
The laser marking machine can print numbers, letters or two-dimensional codes.
(13) Thermal expansion instrument
The tool holder is mainly used for heating the tool and the tool holder and assembling and disassembling the tool.
(14) Tool setting gauge
The tool setting gauge has a function of Barufu reading and writing, and can automatically write tool information on a chip on the tool handle.
(15) Balancing machine
The method is used for balance measurement after the tool is loaded.
After the production line is built, automatic processing, detection and grinding and polishing of various stator blades of the aero-engine in the whole process of on-line production are achieved, adaptive control of production operation is achieved, the requirement of annual blade yield of enterprises is met, and the percent of pass reaches over 90%.
Compared with the prior art, the invention has the advantages and positive effects that:
the production line belongs to an in-line unattended full-automatic line body, and comprises all process contents of a gas compressor manufacturing process, namely, all processes from the output of a blank of a blade to a finished blade to the matching of measurement result data are integrated into an automatic line. The compressor blade is a forged blade, needs more machining parts and comprises the axial diameters of two sides of the blade, a blade body, citron plates on two sides of the blade body and the switching parts of the blade body and the citron plates. The number of devices required for the whole production line and the design process are also complicated.
At present, the technology can realize the material transfer, loading and unloading assembly, positioning and alignment, processing, cleaning, inspection and detection of the aero-engine compressor blade without manual intervention. And the simultaneous mixed line processing of various different blades is realized. The normal maintenance shutdown of the production line is realized, any single machining and material conveying equipment is shut down, and the production line does not stop production.
The digital production line of the compressor blades is built, the purposes of improving the labor production efficiency, stabilizing and improving the product quality, improving the labor conditions, reducing the production floor area, reducing the production cost, shortening the production period and the like are achieved, and the social and economic benefits are remarkably improved.
Drawings
FIG. 1 is a schematic view of a production line scheme according to the present invention;
FIG. 2 is a wire frame diagram of a production line scheme of the present invention.
Reference numerals: 1. the device comprises a blade machining center, 2 a tower type storage bin, 3 a cleaning machine, 4 a sky rail type robot, 5 an automatic loading and unloading station, 6 a tray library, 7 a robot clamping jaw library, 8 a guardrail, 9 a production system industrial personal computer, 10 a three-coordinate measuring machine, 11 a polishing machine, 12 a laser marking machine, 13 a thermal expansion instrument, 14 a tool setting instrument, 15 and a balancing machine.
Detailed Description
Example 1
A design method for a digital full-automatic production line of a compressor blade comprises the following steps:
firstly, according to the structural requirements of the design structure of the blade, the structural characteristics of double shaft necks, citron plates, blade bodies and micro-radius blade shoulder arcs are used for determining that the blade mainly uses a milling and turning composite turning process as a main process, a high-precision numerical control machining center with a five-axis milling and turning composite turning function is selected as main mechanical machining equipment according to the process, and other auxiliary equipment comprises a cleaning machine, a three-coordinate measuring machine, a polishing machine, a laser marking machine, a thermal expansion instrument, a tool setting instrument, a code reader and a balancing machine;
eliminating human factor influence factors, and determining storage and logistics conveying equipment required by an automatic replacement scheme of the process, wherein the storage and logistics conveying equipment comprises a tower type storage bin, a robot arm, a truss guide rail, an automatic loading and unloading station, a tray warehouse, a robot arm clamping jaw warehouse, a guardrail and a system control software machine;
thirdly, determining the production beat according to the requirement of the product capacity, and using TproduceRepresenting the actual production time per year, N representing the part demand quantity per year, omega representing the part production qualification rate, and the production taktperThe calculation formula of (c) can be expressed as:
with DserviceIndicating the number of days per year that the line needs maintenance, TserviceRepresenting the number of annual services, tupRepresenting the time of starting and closing before and after the production line service, the actual production time calculation formula of the production line per year can be expressed as:
Tproduce＝(365-Dservice)×24h-Tservice×tup
the production line maintenance comprises 1 debugging time per week and 1 day maintenance; debugging for 1 time additionally every month, and maintaining for 2 days; the single debugging is carried out for 1 time every year, and the period is 1 day; the maintenance days per year and the service times per year are respectively as follows:
before and after each service, the system is powered on and powered off for tupAnd 24h, the annual running total time of the production line is as follows:
Tproduce＝(365-77)×24h-65×24h＝5352h
fourthly, planning and arranging production line bodies, namely arranging all equipment required by the technological process, balancing the output of the production line according to the principle of minimum equipment, shortest logistics transfer distance, lowest inventory and least production arrangement, and designing the line body arrangement;
whether the production line layout is reasonable or not is mainly measured according to the maximum time loss value of production unbalance, and whether the process is a bottleneck link or not is judged by comparing the production tempo with the production time of a single process;
assuming that a production line has m processes, the standard time consumed by the nth process is tn(n ═ 1,2,3, Λ, m) and the line tact is tperAnd then:
when t isn＞tperIn the process, the time required for finishing the work of the nth process is longer than the production line beat, and the process is a production bottleneck link;
when t isn＝tperThe time required by the processing of the procedure is just equal to the beat of the production line, and the condition is the most ideal state;
when t isn＜tperIn the process, after the nth process finishes working in a production beat, certain residual time is available, which indicates that resources are not fully utilized;
the production line production debugging test is carried out, when all the single equipment meet the requirements of technical conditions, the combined line joint debugging test work is carried out, the correctness of all the programs of the production line is verified, the coordination and unification of all the instructions and corresponding actions are ensured, and the real-time recording and the tracing of production data are realized;
comprehensively evaluating the production line capacity, mainly considering efficiency, cost response degree and product technical specification response degree; evaluating specific indexes of productivity index, machining efficiency matching index, economic index, cost index, delivery cycle, equipment, software, technical scheme and service guarantee; if the production planning requirement is met, jumping to the step (c), and if the production planning requirement is not met, jumping to the step (c);
optimizing the production line, performing simulation verification on the design plan of the production line, analyzing a simulation result, adjusting and optimizing corresponding capacity indexes, production equipment parameters, process methods and logistics transfer processes, and jumping to the fifth step after optimization;
and (8) putting the production line into production and formally executing the batch production tasks.
Example 2
In order to meet the automatic processing, detection and grinding and polishing of 5 aero-engine compressor blades in the whole process of on-line production at the same time and realize self-adaptive control of production operation and the production requirement that the annual production yield of 3.5 thousands of blades reaches 90 percent, an automatic line body consists of 7 blade processing centers, 2 robot grinding and polishing machines, 2 three-coordinate measuring machines, 2 overhead rail type robots, 2 sets of automatic loading and unloading stations, 1 tower type bin, 2 sets of pallet libraries, 1 industrial personal computer of a production system, 1 numerical control laser marking machine, 1 thermal expansion instrument, 1 dynamic balancing machine and 1 tool setting instrument (shown in figures 1 and 2).
The whole production line automatic motion link is a process of transferring workpieces among working procedures, and comprises 10 key motion conversion links, namely, picking up the workpieces from a storage bin by a robot hand, picking up clamps from a clamp station by the robot hand, loading and unloading the workpieces and the clamps in an automatic loading and unloading station, picking up the clamps with the workpieces by the robot hand and installing the clamps with the workpieces in a numerical control machining center, automatically picking up and installing the workpieces with the clamps by the numerical control machining center, picking up the workpieces with the clamps to the automatic loading and unloading station to change the clamps by the robot hand, picking up the workpieces with the clamps to a grinding and polishing device by the robot hand, picking up the workpieces with the clamps to a cleaning device by the robot hand, picking up the workpieces with the clamps to a detection device by the robot hand, and picking up the workpieces with the clamps to finished products to be warehoused.
Taking a single blade as an example, the operation process of the blade in the production line is decomposed as follows:
(1) picking up the robot gripper from the overhead rail type robot to the robot gripper library;
(2) picking up the tray in the tower type stock bin to a tray warehouse by a sky rail type robot;
(3) the robot gripper is replaced from the overhead rail type robot to the robot gripper library (two sets of grippers can be picked up simultaneously);
(4) picking up the clamp from the sky rail type robot hand to the sky rail type robot hand;
(5) the clamp is placed in an automatic loading and unloading station or a tray warehouse by a sky rail type robot;
(6) picking up blade blanks from a tray of a tray warehouse by a sky rail type robot;
(7) the blades are placed on an automatic loading and unloading station by a sky rail type robot;
(8) clamping the blade clamp by an automatic loading and unloading station;
(9) a ceiling rail type robot hand sends a clamp with a blade in the automatic loading and unloading station into a blade machining center for numerical control machining;
(10) taking out the clamp with the blade in the blade machining center by a sky rail type robot, and sending the clamp into an automatic loading and unloading station for unloading the blade;
(11) taking down the blades by a sky rail type robot;
(12) the clamp is sent back to the tray warehouse by a track robot, and the clamp in the next working procedure is picked up;
(13) placing the clamp in an automatic loading and unloading station by a sky rail type robot;
(14) the blades are placed on an automatic loading and unloading station by a sky rail type robot;
(15) clamping the blade clamp by an automatic loading and unloading station;
(16) a ceiling rail type robot hand sends the clamp with the blade in the automatic loading and unloading station into a blade machining center for secondary numerical control machining;
(17) taking out the clamp with the blade in the blade machining center by a head rail type robot hand, and sending the clamp into a robot grinding and polishing machine for grinding and polishing the blade;
(18) taking out the clamp with the blade in the robot grinding and polishing machine by a head rail type robot hand, and sending the clamp into a cleaning machine for cleaning the blade;
(19) taking out the clamp with the blade in the cleaning machine by a sky rail type robot hand, and sending the clamp into a three-coordinate measuring machine for blade measurement;
(20) taking out the clamp with the blade in the three-coordinate measuring machine by a sky rail type robot hand, and sending the clamp into an automatic loading and unloading station for unloading the blade;
(21) taking down the blades by a sky rail type robot;
(22) the clamps in the automatic loading and unloading station are sent back to the tray warehouse by a track robot, and the clamps in the next working procedure are picked up;
(23) the blades are placed on an automatic loading and unloading station by a sky rail type robot;
(24) placing the clamp in an automatic loading and unloading station by a sky rail type robot arm, and connecting the clamp with the blade;
(25) a ceiling rail type robot hand sends the clamp with the blade in the automatic loading and unloading station into a blade machining center for third numerical control machining;
(26) taking out the clamp with the blade in the blade machining center by a sky rail type robot hand, and sending the clamp into a cleaning machine for cleaning the blade;
(27) taking out the clamp with the blade in the cleaning machine by a sky rail type robot hand, and sending the clamp into a laser marking machine for marking;
(28) taking out the clamp with the blade of the laser marking machine by a sky rail type robot hand, and sending the clamp into an automatic loading and unloading station for unloading the blade;
(29) the unloaded blades in the automatic loading and unloading station are sent to a qualified product area of a tray in a buffer area of a tray warehouse by a sky rail type robot;
(30) the tray with full-load blades in the tray warehouse is conveyed into the tower type stock bin by a sky rail type robot arm to finish warehousing
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.
Claims (4)
1. A design method for a digital full-automatic production line of a compressor blade is characterized by comprising the following steps:
firstly, according to the structural requirements of the design structure of the blade, determining the process of milling and machining a composite turning of the blade as a technological process by using the structural characteristics of double shaft necks, citron plates, blade bodies and micro-radius blade shoulder arcs, selecting a high-precision numerical control machining center with a five-axis milling and composite turning function as mechanical machining equipment according to the technological process, wherein other auxiliary equipment comprises a cleaning machine, a three-coordinate measuring machine, a polishing machine, a laser marking machine, a thermal expansion instrument, a tool setting instrument, a code reader and a balancing machine;
eliminating human factor influence factors, and determining storage and logistics conveying equipment required by an automatic replacement scheme of the process, wherein the storage and logistics conveying equipment comprises a tower type storage bin, a robot arm, a truss guide rail, an automatic loading and unloading station, a tray warehouse, a robot arm clamping jaw warehouse, a guardrail and a system control software machine;
thirdly, determining the production beat according to the requirement of the product capacity, and using TproduceRepresenting the actual production time per year, N representing the part demand quantity per year, omega representing the part production qualification rate, and the production taktperIs expressed as:
fourthly, planning and arranging production line bodies, namely arranging all equipment required by the technological process, balancing the output of the production line according to the principle of minimum equipment, shortest logistics transfer distance, lowest inventory and least production arrangement, and designing the line body arrangement;
the production line production debugging test is carried out, when all the single equipment meet the requirements of technical conditions, the combined line joint debugging test work is carried out, the correctness of all the programs of the production line is verified, the coordination and unification of all the instructions and corresponding actions are ensured, and the real-time recording and the tracing of production data are realized;
comprehensively evaluating the production line capacity, considering the efficiency, the cost response degree and the product technical specification response degree; evaluating specific indexes of productivity index, machining efficiency matching index, economic index, cost index, delivery cycle, equipment, software, technical scheme and service guarantee; if the production planning requirement is met, jumping to the step (c), and if the production planning requirement is not met, jumping to the step (c);
optimizing the production line, performing simulation verification on the design plan of the production line, analyzing a simulation result, adjusting and optimizing corresponding capacity indexes, production equipment parameters, process methods and logistics transfer processes, and jumping to the fifth step after optimization;
putting the production line into production and formally executing batch production tasks; step III, with DserviceIndicating the number of days per year that the line needs maintenance, TserviceRepresenting the number of annual services, tupThe time of starting and closing before and after the production line service is expressed, and the actual production time calculation formula of the production line every year is expressed as follows:
Tproduce＝(365-Dservice)×24h-Tservice×tup
the production line maintenance comprises 1 debugging time per week and 1 day maintenance; debugging for 1 time additionally every month, and maintaining for 2 days; the single debugging is carried out for 1 time every year, and the period is 1 day; the maintenance days per year and the service times per year are respectively as follows:
before and after each service, the system is powered on and powered off for tupAnd 24h, the annual running total time of the production line is as follows: t isproduce(365-77) × 24h-65 × 24h ═ 5352 h; judging whether the production line layout is reasonable according to the maximum time loss value of production unbalance, and judging whether the process is a bottleneck link or not by comparing the production beat with the production time of a single process;
assuming that a production line has m processes, the standard time consumed by the nth process is tn(n＝1,2,3…, m), line tact tperAnd then:
when t isn＞tperIn the process, the time required for finishing the work of the nth process is longer than the production line beat, and the process is a production bottleneck link;
when t isn＝tperThe time required by the processing of the procedure is just equal to the beat of the production line, and the condition is the most ideal state;
when t isn＜tperIn the process, after the nth process finishes working in one production beat, a certain residual time is still available, which indicates that resources are not fully utilized.
2. A compressor blade digital full-automatic production line designed by the method of claim 1, which is characterized in that: the production line is provided with an in-line device and an out-line device, the in-line device is used for automatic production, and the out-line device is used for tool preparation;
the inline device includes: the device comprises a blade machining center, a tower type storage bin, a cleaning machine, a robot arm, a guide rail, an automatic loading and unloading station, a tray library, a robot arm clamping jaw library, a guardrail, a production system industrial personal computer, a three-coordinate measuring machine, a polishing machine and a laser marking machine;
the off-line device includes: thermal expansion instrument, tool setting instrument and balancing machine.
3. The compressor blade digital full-automatic production line of claim 2, characterized in that: the blade machining center is a vertical five-axis blade machining center, a main shaft is 30000rpm and is provided with a double-drive shaft at 4000rpm, the blade machining center has a turning function, is provided with an automatic workpiece exchange and tray pre-selection station, and is provided with a high-precision measuring head and a cutter identification chip, and has a main shaft monitoring function, a high-pressure internal cooling function and a cooling liquid constant temperature function; all the characteristics of the blade, including round handle, screw thread, profile, air inlet and outlet edges, blade root, blade crown and switching are processed and finished on the blade processing center.
4. The compressor blade digital full-automatic production line of claim 2, characterized in that: the industrial personal computer of the production system comprises uplink and downlink control, uplink control order production cycle production scheduling, various parts and tools storage and consumption, equipment operation data acquisition and product quality data storage for statistics and analysis; the industrial control machine of the production system generates a brand new motion control instruction according to the actual order requirement and sends the brand new motion control instruction to each device in the production line, and the device can automatically run according to the program after receiving the instruction.
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| CN201911180288.4A CN110936174B (en) | 2019-11-27 | 2019-11-27 | Design method of compressor blade digital full-automatic production line |
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| CN113589778A (en) * | 2021-06-01 | 2021-11-02 | 巨轮(广州)智能装备有限公司 | Intelligent processing method and intelligent processing system |
| CN114643382B (en) * | 2021-12-24 | 2023-12-26 | 无锡黎曼机器人科技有限公司 | Automatic blade batch loading and unloading method based on robot system |
| CN115055979A (en) * | 2022-06-17 | 2022-09-16 | 广东省离散智造科技创新有限公司 | Processing production line and processing method of artware |
| CN115365793B (en) * | 2022-10-24 | 2023-02-28 | 石家庄欧亚惠通滤清器有限公司 | Extrusion type assembling device for spiral-flow tube type prefilter |
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